Convertible applicating machine

ABSTRACT

A machine for packaging multiple containers wherein a flexible carrier stock is fed across a jaw drum. A plurality of containers are also moved through the machine whereby the carrier is subsequently positioned over the plurality of containers so that flexible carrier stock engages with one of the containers to form a package. The jaw drum and/or a connected feed drum are preferably adjustable to accommodate a range of container sizes and carrier configurations.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/688,591, filed 15 Jan. 2010, which claims the benefit of U.S.Provisional Application No. 61/149,266 filed on 2 Feb. 2009. Theseapplications are hereby incorporated by reference herein in its entiretyand is made a part hereof, including but not limited to those portionswhich specifically appear hereinafter.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a machine for unitizing a plurality ofcontainers using a flexible container carrier.

2. Description of Prior Art

Container carriers connect two or more containers into a sturdy unitizedpackage of containers. Carriers are generally planar arrays of rings,sometimes referred to as “six-pack carriers,” typically formed from athermoplastic sheet material. Carriers are applied to containers ofvarious sizes and shapes along various points along the sidewall orunder the chime of the container. A preferable machine would be capableof application of a container carrier to a wide range of containersizes.

Conventional carriers are arranged in aligned arrays of longitudinalrows and transverse ranks of container receiving apertures. A commonarrangement is two rows of three ranks of longitudinally andtransversely aligned container receiving apertures forming six totalcontainer receiving apertures and a “six-pack.” Other commonconfigurations include two rows of four ranks forming an eight containermultipackage and three rows of four ranks forming a twelve containermultipackage.

Conventional applicating machines generally include a circular jaw drumused to apply carriers to individual containers. The conventional jawdrum is typically fixed into position on the applicating machine and fedwith a reel or box of a generally continuous container carriers. Suchconventional applicating machines typically include an infeed conveyorfor supplying a plurality of containers.

The string of carriers are then traditionally applied to the containersand, following application, cut into a desired package configuration.The resulting package is then fed into a turner-diverter that movesand/or rotates the package to a correct position for placement on apallet or similar shipping unit.

Prior art applicating machines, systems and methods generally requireseveral different versions or configurations of machines to accommodatedifferent container carrier, package sizes and package configurations.Machines are traditionally a limitation on the range of containerdiameters, size of package or configuration of package that can beeffectively packaged by a single system.

Finally, different machines or complex set-up procedures would also berequired for containers having different sizes, heights and/or widths,resulting in different lengths, called “pitch” herein, between eachadjacent container. As such, different machines and/or set-up proceduresare traditionally required to bring the carrier to the correct positionaround the container.

SUMMARY OF THE INVENTION

A machine for packaging multiple container sizes, using multiplecontainer carriers and/or multiple package sizes includes a carrier thatmoves through a jaw drum. The carrier is positioned around a perimeterof the jaw drum, and rotates onto uniform groups of containers. Thecontainers are assembled and unitized in a single package. After a briefset-up period, a uniform group of containers having a second physicalsize requiring a second container carrier size may be packaged with themachine according to this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and objects of this inventionwill be better understood from the following detailed description takenin conjunction with the drawings wherein:

FIG. 1 is a side view of a machine for packaging containers according toone preferred embodiment of this invention;

FIG. 2 is a side perspective cutaway view of a jaw drum according to onepreferred embodiment of this invention;

FIG. 3 is a front schematic view of the jaw drum relative to a pluralityof containers;

FIG. 4 is a side view of a package of containers using a rim-appliedcarrier configuration;

FIG. 5 is a side perspective view of a portion of a jaw drum accordingto one preferred embodiment of this invention;

FIG. 6 is a side perspective view of a first jaw according to onepreferred embodiment of this invention;

FIG. 7 is a side perspective view of a second jaw according to onepreferred embodiment of this invention;

FIG. 8 is a side perspective view of a reversible jaw according to onepreferred embodiment of this invention;

FIG. 9 is a side schematic view of the positions of first jaws andsecond jaws on a jaw drum relative to containers having a first pitchand a second pitch, respectively; and

FIG. 10 is a side perspective view of a feed system according to onepreferred embodiment of this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 shows a machine for packaging multiple containers in a carrieraccording to one preferred embodiment of this invention. As shown,carrier stock 15 moves through machine 10, specifically through jaw drum40, where it is applied to containers and then separated intoindividual, unitized packages. According to one preferred embodiment ofthis invention, if a uniform group of like-sized containers having adifferent size requires packaging and/or if a different carrier isrequired, a separate machine is unnecessary as machine 10 may be quicklyreconfigured, following various adjustments to machine 10, as describedbelow.

Therefore, the machine 10 for packaging multiple containers in multiplesize packages according to this invention permits the use of a singlemachine in combination with a variety of sizes of containers and/orsizes and configurations of carriers and/or packages. Traditionalmachines are typically fifteen or more feet long and six or more feetwide, therefore a reduction in the number of machines required in apackaging plant significantly reduces the required working floor spacewithin the plant. In addition, quick and generally toolless set-up andchangeover results in more efficient packaging operations.

Carrier preferably moves through machine 10 from a reel where carriersare dispersed in a continuous string of carrier stock 15 and ultimatelyto packages where each carrier is separated into a unitized package,each package containing a plurality of uniform containers. A typicalconfiguration for a package is a “six-pack” containing two longitudinalrows of containers in three transverse ranks. Additional desiredpackages such as four-packs, eight packs and twelve packs may beunitized using machine 10 according to this invention, and suchadditional sizes of packages are limited only by the consumer market forsuch additional sizes.

Carrier (and carrier stock) is preferably constructed from a flexibleplastic sheet, such as low-density polyethylene. The flexible plasticsheet is punched or otherwise formed into a plurality of containerreceiving apertures aligned in transverse ranks and at least twolongitudinal rows to form a continuous sheet of carriers. The containerreceiving apertures are preferably oriented in a longitudinal directionwith respect to carrier. Carrier may also include features such as ahandle for holding carrier along either a side or a top of the packageand/or a merchandising panel for displaying product and/or promotionalinformation. Additionally, features such as tear tabs and perforationsmay be included in the carrier to ease removal of the containers fromcarrier.

According to one preferred embodiment of this invention, machine 10 forpackaging multiple containers includes moving carrier stock 15 throughmachine 10 from a reel stand (not shown). Carrier stock 15 then entersmachine 10 across feed drum 70 and into jaw drum 40. Followingapplication to containers, carrier stock 15 is divided into individualcarriers using cutoff wheel 100 resulting in individually unitizedpackages of a desired size which are then dispersed to a case packer(not shown) using turner/diverter 130. Feed drum 70 and jaw drum 40 ofmachine 10 are described in detail in the following description ofpreferred embodiments of this invention, including features that permitmachine 10 to address a wide range of packaging requirements.

Machine 10 includes an input conveyor 20 for conveying the containerslongitudinally into a platform of machine 10, in preferably twolongitudinal rows, and an output conveyor 30 for conveying thecontainers longitudinally from the platform after the carrier stock hasbeen applied. According to a preferred embodiment of this invention,star wheel 90 is positioned on each side of machine 10 to acceptcontainers from input conveyor 20. Star wheel 90 serves to locate thecontainers for proper application of carrier stock 15 to suchcontainers. The plurality of containers moves through machine 10 andeach container is spaced apart from an adjacent container by star wheel90. The spacing between adjacent containers as they enter machine 10depends upon the relative sizing and configuration of star wheel 90which may be exchangeable and/or sized to accommodate the largestdiameter container to be used in machine 10. Star wheel 90 may bereplaceable with substitute star wheels having a different thickness ordifferent surface geometry, such as to accommodate non-conventionalcontainer shapes, such as contoured cans. As discussed in more detailbelow, carrier stock 15 is subsequently positioned over the plurality ofcontainers whereby each container receiving aperture engages with one ofthe containers to form a package having a predetermined number ofcontainers.

Jaw Drum

The plurality of containers proceed from star wheel 90 to beneath jawdrum 40, as shown in FIG. 2, for application of carrier stock 15 aroundthe containers, such as shown in FIG. 3, resulting in a unitized packageshown in FIG. 4. Carrier stock 15 proceeds from feed drum 70, discussedin more detail below, to jaw drum 40, particularly to jaw pairs 45located radially about jaw drum 40. Jaw drum 40, such as shown in FIG.2, preferably comprises a cylindrical member rotatable about ahorizontal axis which transports carrier stock 15 from feed drum 70 tothe plurality of containers which flow through jaw drum 40. A pluralityof j aw pairs 45 are preferably equally spaced around a perimeter of jaw drum 40. Radial positions of jaw pairs 45 around the perimeter of jawdrum 40 are preferably permanently fixed.

According to one preferred embodiment of this invention, each jaw pair45 is movable between a closed position and an open position along anaxis parallel to the horizontal axis of rotation of jaw drum 40. Theclosed position comprises a relative position of jaw pair 45 when amoveable jaw is in a closest desired position relative to a fixed jaw.The open position comprises a relative position of jaw pair 45 when themoveable jaw is in a farthest desired position relative to the fixedjaw. As a result of a cammed relationship between the fixed jaw and themoveable jaw, the relative position of the moveable jaw with respect tothe fixed jaw changes as jaw drum 40 is rotated through a full 360□rotation.

Each jaw pair 45 is configured to grip carrier stock 15 through eachtransverse pair of container receiving apertures in carrier stock 15.The circumferential spacing between adjacent jaw pairs 45 is preferablyapproximately equal to a pitch of carrier, i.e., the distance betweenadjacent centers of container receiving openings. The lateral spacingbetween the moveable jaw and the fixed jaw in the closed position ispreferably slightly less than a width between transverse pairs ofcontainer receiving apertures. Carrier stock 15 is engaged with jawpairs 45 of jaw drum 40 immediately prior to application to containers.

As such, jaw drum 40 is adapted to draw the flexible carrier stock 15from feed drum 70 and apply the flexible carrier stock 15 to theplurality of containers. According to a preferred embodiment of thisinvention, jaw pairs 45 preferably comprise a plurality of firstremovable jaws 40 connected around a circumference of jaw drum 40, suchas shown in FIGS. 2, 3 and 5. The plurality of first removable jaws 50are preferably exchangeable with plurality of second removable jaws 55,such as shown in FIG. 7. According to one preferred embodiment of thisinvention, second removable jaws 55 include a different jaw height thanfirst removable jaws 50. More particularly, as shown in FIGS. 6 and 7,second removable jaws 55 include a greater jaw height than firstremovable jaws 50.

According to one preferred embodiment of this invention, a plurality ofpairs of locating pins 60 positioned around the circumference of jawdrum 40, each pair of locating pins 60 removably receiving a firstremovable jaw 50 or a second removable jaw 55 of the jaw pairs 45. Eachjaw pair 45 preferably further includes a pair of slots 46 formed inbody 48 of a respective removable jaw 50, 55 for engaging the pair oflocating pins 60 on jaw drum 40.

As shown in FIG. 5, jaw drum 40 and/or jaw pairs 45 may further includeretaining pin 65 biasing removable jaws 50, 55 into position on jaw drum40. Retaining pin 65 may be spring loaded or otherwise biased so as tofacilitate placement and removal of jaw pairs 45 with respect to jawdrum 40. Preferably, jaw pairs 45 are removable and replaceable in atool-less manner by simply manually manipulating retaining pin 65 torelease each jaw of the respective removable jaws 50, 55 from jaw drum40.

According to a preferred embodiment of this invention shown in FIG. 8,each jaw of jaw pairs 45 may comprise a jaw having first removable jaws50 and second removable jaws 55 located on opposite ends of a commonbody 48. In such a manner, a respective jaw may be reversed on jaw drum40 depending on whether first removable jaws 50 or second removable jaws55 are desired for the particular application.

FIG. 9 schematically shows the result of replacing first removable jaws50 with second removable jaws 55. As shown, first removable jaws 50having a first jaw height result in a first pitch 150. Likewise, secondremovable jaws 55 having a second, greater jaw height result in secondpitch 160. As a result, a first set of containers having first pitch150, or distance between centers of adjacent containers, may be packagedusing jaw drum 40. Should a second set of containers having a secondpitch 160 be desired, then second removable jaws 55 may replace firstremovable jaws 50 for setting the desired pitch. In this manner, largerdiameter containers, having the second pitch 160, may be packaged on thesame machine as a smaller diameter containers having the first pitch150.

As jaw pairs 45 move with the rotation of jaw drum 40 from a closedposition to an open position, container receiving apertures withincarrier stock 15 stretch to accommodate a container. Carrier stock 15 ina stretched condition is positioned over a plurality of containers sothat each container receiving aperture engages with one container. Uponengagement with the containers, carrier stock 15 is released from jawpair 45 and grips a perimeter of container, either around a chime in arim-applied carrier (RAC) configuration, such as shown in FIG. 4, oraround a sidewall in a sidewall-applied carrier (SAC) configuration (notshown).

FIG. 3 shows a position of jaw drum relative to containers for a RACconfiguration. In a RAC configuration, jaw drum 40 is positioned so thatjaw pairs 45 properly engage containers to position carrier stock 15about a chime of each container as shown in FIG. 4. When a largerdiameter container requires packaging, jaw pairs 45 may be swapped out,such as between first removable jaws 50 and second removable jaws 55 tocreate new pitch options as shown schematically in FIG. 9.

Feed Drum

As carrier stock 15 is dispersed from reel stands (not shown) to jawdrum 40, feed drum 70 is used to maintain tension in the carrier stock15. Feed drum 70, as shown in detail in FIG. 10, preferably includespinch roller 80 connected upstream of jaw drum 40 for feeding theflexible carrier stock 15 to jaw drum 40. Pinch roller 80 may comprise adriven rubber roller clamped against a free metal roller to positivelyadvance carrier stock 15 at a desired speed.

Carrier stock 15 preferably further extends around dancer arm 85connected with respect to pinch roller 80. Dancer arm 85 preferablymeasures and maintains a relative tension in carrier stock 15 as it ispulled from the reel stand and advanced to jaw drum 40. Specifically,speed sensor 75 is preferably connected with respect to dancer arm 85for controlling a speed of pinch roller 80 based upon a speed of jawdrum 40. Cam 83 may be additionally connected with respect to dancer arm85 and speed sensor 75 for providing carrier stock speed feedback topinch roller 80.

In this manner, feed drum 70 may provide a proper speed of carrier stock15 depending on the relative pitch 150, 160 required and the relativesize of jaw pairs 45 required. A plurality of first removable jaws 50may thus correspond with a first plurality of containers having a firstpitch 150 and a first application speed and a plurality of secondremovable jaws 55 may correspond with a second plurality of containershaving a second pitch 160 and a second application speed. Speed sensor75 thereby automatically adjusts a speed of pinch roller 80 based on adesired application speed.

As described above, one or more operative components of machine 10 arepreferably adjustable to permit packaging of containers having differentsizes, such as heights and diameters and carriers having differentsizes. In each of these different applications, multiple components ofmachine 10 may be adjusted, replaced and/or interchanged to permitapplication of carrier stock 15 to containers.

While in the foregoing specification this invention has been describedin relation to certain preferred embodiments thereof, and many detailshave been set forth for purposes of illustration, it will be apparent tothose skilled in the art that the invention is susceptible to additionalembodiments and that certain of the details described herein can bevaried considerably without departing from the basic principles of theinvention.

1. A machine for packaging a plurality of containers into packages usingflexible carrier stock, the machine comprising: a feed drum adapted tofeed the flexible carrier stock; a jaw drum adapted to draw the flexiblecarrier stock from the feed drum and apply the flexible carrier stock tothe plurality of containers; a plurality of first removable jawsconnected around a circumference of the jaw drum, the plurality of firstremovable jaws exchangeable with a plurality of second removable jaws,the second removable jaws having a different jaw height than the firstremovable jaws, wherein the first removable jaws correspond with a firstplurality of containers having a first pitch and the second removablejaws correspond with a second plurality of containers having a secondpitch.
 2. The machine of claim 1 further comprising: a plurality ofpairs of locating pins positioned around the circumference of the jawdrum, each pair of locating pins removably receiving a first removablejaw of the plurality of first removable jaws.
 3. The machine of claim 2further comprising: a pair of slots formed in the first removable jawsfor engaging the pair of locating pins.
 4. The machine of claim 1further comprising: a retaining pin biasing the first removable jawsinto position on the jaw drum.
 5. A machine for packaging a plurality ofcontainers into packages using flexible carrier stock, the machinecomprising: a feed drum adapted to feed the flexible carrier stock, thefeed drum further including a pinch roller connected with respect to thejaw drum for feeding the flexible carrier stock to the jaw drum; adancer arm connected with the pinch roller; and a speed sensor connectedwith respect to the dancer arm for controlling a speed of the pinchroller based upon a speed of the jaw drum; a jaw drum adapted to drawthe flexible carrier stock from the feed drum and apply the flexiblecarrier stock to the plurality of containers; a plurality of jawsconnected around a circumference of the jaw drum.
 6. The machine ofclaim 5 further comprising a plurality of first removable jawsexchangeable with a plurality of second removable jaws, wherein thefirst removable jaws correspond with a first plurality of containershaving a first pitch and the second removable jaws correspond with asecond plurality of containers having a second pitch.
 7. The machine ofclaim 5 wherein the pinch roller comprises a driven rubber rollerclamped against a free metal roller.
 8. The machine of claim 5 furthercomprising: a cam connected with respect to the dancer arm, the camconnected with respect to the speed sensor for providing carrier stockspeed feedback.
 9. A machine for packaging a plurality of containersusing flexible carrier stock, the machine comprising: a jaw drum adaptedto draw the flexible carrier stock and apply the flexible carrier stockto the plurality of containers; and a plurality of first removable jawsand a plurality of second removable jaws, wherein the first removablejaws correspond with a first plurality of containers having a firstpitch and the second removable jaws correspond with a second pluralityof containers having a second pitch.
 10. The machine of claim 9 whereinthe jaw drum further comprises: a retaining pin biased against eachremovable jaw for tool less removal of the plurality of removable jaws.11. The machine of claim 9 further comprising: a pinch roller connectedwith respect to the jaw drum for feeding the flexible carrier stock tothe jaw drum; a dancer arm connected with the pinch roller; and a speedsensor connected with respect to the dancer arm for controlling a speedof the pinch roller based upon a speed of the jaw drum.
 12. The machineof claim 11 further comprising: a plurality of first removable jawscorresponding with a first plurality of containers having a first pitchand a first application speed; and a plurality of second removable jawscorresponding with a second plurality of containers having a secondpitch and a second application speed, the speed sensor automaticallyadjusting the speed of the pinch roller based on a desired applicationspeed.
 13. The machine of claim 9 wherein each removable jaw of theplurality of removable jaws comprise a first removable jaw and a secondremovable jaw located on opposite ends of a common body.